Excel HE C24, User Manual

Page 1: ... and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers For the very latest copy of literature for specification purposes please visit our website www idealboilers com where you will be able to download the relevant information in pdf format HE C24 C28 C32 For details of document amendments refer to page 3 Novembe...

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Page 3: ...2 excel HE Installation and Servicing ...

Page 4: ...es Page 7 Optional Extra Kits Addition of High Level Flue Outlet Kit Page 40 Frame 63 PCB Replacement Note added re antistatic precautions Page 42 Frame 66 Air Pressure Switch Replacement New photograph added showing correct orientation of air pressure switch Users Guide Page 2 Important Notes Additon of two new bullets into important notes Ideal Stelrad Group reserve the right to vary specificati...

Page 5: ...AP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body Table 2 Performance Data Central Heating HE C24 Max HE C24 Min HE C28 Max HE C28 Min HE C32 Max HE C32 Min Max Burner pressure hot G20 mbar in w g 13 4 5 3 2 2 0 9 10 5 4 2 1 5 0 6 12 9 5 2 1 6 0 6 Input based on nett CV kW btu h 24 4 83 300 29 0 98 900 33 4 114 000 Input based ...

Page 6: ...3 12 Inhibitor 12 Central heating mode Heat input to be calculated For assistance see Technical Helpline on the back page Page Burner operating pressure measure and record Central heating flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reducer 11 Hot water mode Heat input n a Max operating burner pressure n a Max operating water pressu...

Page 7: ...ppropriate e g gloves safety footwear During all manoeuvres and handling actions every attempt should be made to ensure the following unless unavoidable and or the weight is light Keep back straight Avoid twisting at the waist Avoid upper body top heavy bending Always grip with the palm of the hand Use designated hand holds Keep load as close to the body as possible Always use assistance if requir...

Page 8: ... Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation fo...

Page 9: ...ns of BS 5440 1 2000 In IE refer to I S 813 2002 The following notes are intended for general guidance 1 The boiler MUST be installed so that the terminal is exposed to external air 2 It is important that the position of the terminal allows the free passage of air across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 4...

Page 10: ...arance The minimum front clearance when built in to a cupboard is 5mm 1 4 from the cupboard door but 450mm 17 3 4 overall clearance is still required with the cupboard door open to allow for servicing Bottom clearance Bottom clearance after installation can be reduced to 5mm However 100mm must be available for servicing Where the space into which the boiler is going to be installed is less than th...

Page 11: ... in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS 5449 Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating or hot water When thermostatic radiator valves are used the space heating temperature control over ...

Page 12: ...l the minimum system design pressure is reached 1 0 bar if the system is to be pre pressurised DOMESTIC HOT WATER 1 The domestic hot water service must be in accordance with BS 5546 and BS 6700 2 Refer to Table 1 for minimum and maximum working pressures 3 The boilers are suitable for connection to most types of washing machine and dishwasher appliances 4 When connecting to suitable showers ensure...

Page 13: ...hould be fitted into the boiler cold supply within the requirements of the local water company The use of artificially softened water however is not permitted Ideal Stelrad Group recommend the use of Fernox Qantomat GE Betz Sentinel Combiguard and Calmag CalPhos I scale reducing devices which must be used in accordance with the manufacturers instructions For further information contact 7 BOILER AS...

Page 14: ...stallation and Servicing 8 BOILER ASSEMBLY Exploded View ex7484 33 26 25 35 29 30 40 46 19 50 44 58 20 21 57 9 6 17 51 2 5 1 56 52 43 Data Plate 45 42 10 8 41 53 Flue gas sampling point 28 31 36 27 34 User Data Plate INSTALLATION ...

Page 15: ... off G Gas cock washer 1 off H Wallplug 2 off Pack A Contents A The boiler B Hardware pack and fittings C Wall mounting plate D These Installation Servicing User s instructions E Wall mounting template Pack B Contents A Flue turret B Flue terminal F 1 year guarantee form G Flue Restrictor 1 off 24 kW 39mm 28 kW 43mm 32 kW 45mm nm7407 B C E A D F G ix7408 A B J No 14x2in wood screw rd hd black 2 of...

Page 16: ...sary if using one or more D extension duct packs RH Side LH Side Rear Rear flue length Side flue length ix7416 450 171 2 25 1 177 7 119 43 4 X R Side flue length 450 171 2 25 1 331 13 L 1 Cut and remove straps 2 Remove literature and wall mounting template 3 Lift off outer sleeve 4 Lift off top tray 5 Leave boiler in bottom tray to protect exposed boiler connections during wall hanging Note Hardwa...

Page 17: ...d the flue centre line onto the side wall and measure in 175mm for standard installation Note If using stand off kit distance increases to 211mm 13 WALL MOUNTING TEMPLATE 12 FLUE ASSEMBLY Exploded View An optional flue duct extension kit is required for wall thicknesses greater than LH Side 420mm 161 2 RH Side 630mm 243 4 Rear 600mm 235 8 Rear flue arrangement shown LEGEND 1 Flue Elbow 2 Flue Asse...

Page 18: ...ckness X Refer to Frame 11 2 Add 105mm 4 1 8 to dimension X and measuring from the ring cut both outer and inner tube Ensure support spring clip is in position to facilitate cutting 3 To ensure the tube is cut square mark the flue all the way around 16 CUTTING THE FLUE LH OR TO RH SIDE Wall thicknesses of 114 to 420mm LH side or to 630mm RH side Note If using the extension ducts go to Frame 17 18 ...

Page 19: ...tension is required 4 Measure and mark the flue length required onto the flue measuring from the ring near the terminal Refer to Frames 11 and 16 for the detail of flue length calculation 5 To ensure a square cut mark the flue all the way around 6 De burr the cut edges 19 FITTING THE KIT 17 FLUE EXTENSION DUCTS For flue lengths greater than 775mm Pack D Flue extension duct kit contents Note Side f...

Page 20: ... made This is achieved by using either Flat roof weather collar or Universal weather collar ACCESSORIES Flue Duct Extension Kits are available for flue lengths extending beyond 1m These packs contain 1m extension ducts and may be cut to the desired length If the offset vertical option is used an elbow Kit is required For a full accessories list refer to page 7 Optional Extras and Frame 23 Flue Arr...

Page 21: ...UE TERMINAL POSITION 610 mm min ex7531 610 mm min ex8389 Flat Roof 600mm The terminal should be positioned so that products of combustion can safely disperse at all times Pluming may occur at the termination so where possible terminal positions where this could cause a nuisance should be avoided Minimum dimensions are shown below 23 FLUE ARRANGEMENT Note The equivalent flue length resistance of th...

Page 22: ...rew ENSURING THEGASKETSINTHEBOILERFLUEOUTLETARE CORRECTLYFITTED 4 Push fit the 60 100 to 80 125 adaptor G supplied separately into the vertical connector 5 Push fit extension duct H if required supplied separately and the roof flue kit assembly A into the adaptor G 6 If the last extension duct requires cutting measure the distance outer ducts between the duct and the terminal and add 100 mm to thi...

Page 23: ...Screws No 10x2 4 off 1 Fit black outer wall seal over terminal and ensure the retaining rim is located in the terminal depression 2 Fit flue pipe assembly through the hole previously cut in wall 3 Fit white inner wall seal and push up to inner wall 4 Fit turret to boiler see Frame 30 and to the flue pipe assembly 5 Fit outer wall sealing plate over outer wall seal and retain with the 4 screws and ...

Page 24: ...drain pipe remove plastic plug from connection Connection to the boiler is by push fit into the rubber collar protruding from the boiler Ensure that the condensate trap is full of water before commissioning the boiler Refer to Frame 30 The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler throughout its length The drainage pipework must be arranged so that o...

Page 25: ...29 CONNECTIONS CH DHW AND GAS Notes 1 Central Heating For heating loads in excess of 60 000 Btu h use 28mm x 22mm connectors to connect the boiler flow and return pipes to 28mm system pipework 3 5 4 1 2 Flue Restrictor A ex7953 2 Central Heating Domestic Hot Water and Gas Do not subject any of the isolating valves to heat as the seals may be damaged 3 Gas Refer to Frame 2 for details of the gas co...

Page 26: ...e control box wiring is protected 6 Ensure the pressure indicated on the pressure gauge is between 1 and 1 5 bar Domestic Hot Water 1 Close all hot water draw off taps 2 Open the cold water inlet valve 3 Slowly open each draw off tap and close only when clear and air bubble free water flows out The pressure relief valve is located at the bottom LHS of the boiler Remove front panel See Frame 44 The...

Page 27: ...ng external to the boiler MUST be in accordance with the current I E E BS7671 Wiring Regulations and any local regulations 34 INTERNAL WIRING INCOMING MAINS WIRING DETAIL To gain access to the power supply and external controls terminal block 1 Remove the screws and the cover panel 2 Remove the control box fixing screws 3 Pull the control panel forward 4 Remove the screws and the service panel Mai...

Page 28: ...ched on Central heating systems fitted wholly inside the house do not normally require frost protection as the house acts as a storage heater and can normally be left at least 24 hours without frost damage However if parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system To maintain frost prote...

Page 29: ...6 7 8 NAC1 Ignitor Gas Valve I F 1 2 Overheat Stat 1 2 Condensate Blockage Thermistor 1 2 3 AC Pump 6 7 1 3 4 5 8 SIT Sigma 845 Gas Valve In line Spade 1 3 2 Divertor Valve 1 2 Pump Proving Switch 1 2 DHW Flow Switch 1 2 Flow Thermistor 1 2 DHW Flow Thermistor 1 2 3 4 5 6 7 8 1 2 Switch SPST Controls Earth Chassis Earth Burner Earth 1 2 1 2 3 4 5 6 NAC Lead 17 18 19 20 21 22 23 24 25 26 27 28 29 3...

Page 30: ...hite y yellow g y green yellow DV Live 1 DV Live 2 DV Neutral Pump Live Pump Neutral Pump Earth Mod Mod GV IGN Live IGN Neutral GV Neutral GV Neutral GV Earth APS APS Fan Neutral Fan Live 0V Analog input 24V 5V 3 2 1 Control 0 OH OH Flow Flow DHW Temperature DHW Temperature PPS PPS DHW Flow DHW Flow Ionisation Burner PE Chassis PE Supply Earth R2 SWL R1 F1 Live feed F2 Frost SWL Supply Neutral Sup...

Page 31: ...ional lights 1 3 Fault indication light 2 F Optional programmer 10 Switch the electricity supply ON and check all external controls are calling for heat 11 CENTRALHEATING Set the main switch and CH thermostat knob B to position shown in diagram and switch the boiler on off switch A to ON The boiler control should now go through its ignition sequence until the burner is established Green operationa...

Page 32: ...y all radiator handwheel valves or TRVs if fitted be set fully open that all lockshield valves be set a half turn open Make minor adjustments to each radiator to achieve the same differential on all Finally set the system controls to the users requirements If an optional programmer kit is fitted refer to the instructions supplied 40 INITIAL LIGHTING CONTINUED 13 DOMESTIC HOT WATER With the boiler ...

Page 33: ...re Explain that the dial on the boiler control panel indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated In this event a registered local heating installer should be consulted WARNING Do not fire the boiler if the pressure has reduced to zero from the original setting 9 After insta...

Page 34: ...rds and forward at the bottom to remove 1 Slacken the 2 top and 2 bottom fixing screws from the LH and RH side panels and remove the panels 2 To remove the sealing panel remove the 4 fixing screws from the front 3 Remove the sealing panel by pulling forward to disengage rear clips 4 Remove the fixing screws retaining the inner sealing panel and remove the panel taking care not to damage the front ...

Page 35: ...trical leads from the fan 4 Disconnect APS sensing tube 5 Inspect venturi and fan and clean as necessary 6 Reassemble in reverse order 46 THE CONTROL BOX IN THE SERVICING POSITION 1 Remove the screws and the cover panel 2 Remove the control box fixing screws 3 Pull the control panel forward 4 Remove the control box lid fixing screws and remove lid ix7424 1 2 47 FAN AND VENTURI REMOVAL AND CLEANING...

Page 36: ...suitable tool as supplied in the standard British Gas Flue brush kit clean between the heat exchanger fins 2 Access to the base of the combustion chamber is now possible Brush clean any deposits from the base of the combustion chamber and remove any loose deposits 3 Check the condition of the combustion chamber insulation Any cracked or damaged pieces should be replaced 50 RE ASSEMBLY 1 Refit the ...

Page 37: ...RMISTOR REPLACEMENT 1 Refer to Frame 51 2 Remove the boiler front side and sealing panels Refer to Frame 44 and 45 3 Carefully pull off the green electrical connection 4 Unscrew the condensate blockage thermistor 5 Fit new condensate blockage thermistor complete with new washer 6 Re assemble in reverse order 7 Check the operation of the boiler Refer to Frame 50 and 51 53 FAN AND FAN SUPPRESSOR REP...

Page 38: ...ition Refer to Frame 46 3 Carefully separate the in line connector from the detection lead 4 Carefully pull off the two ignition leads from the side of the ignition unit 55 BURNER REPLACEMENT 1 Refer to Frame 51 2 Remove the boiler front side and sealing panels Refer to Frames 44 and 45 3 Overheat Thermostat a Carefully pull off the 2 electrical connections b Unclip thermostat from pipe c Fit 2 el...

Page 39: ...ew ignition electrodes 9 Re assemble in reverse order 10 Check the operation of the boiler Refer to Frame 50 and 51 58 FLAME DETECTION ELECTRODE REPLACEMENT 1 Refer to Frame 51 2 Remove the boiler front side and sealing panels Refer to Frames 44 and 45 Put the control box into the servicing position Refer to Frame 46 3 Carefully separate the in line connector from the detection lead 4 Carefully pu...

Page 40: ...e 7 Remove the 2 gas control valve bracket fixing screws 8 Withdraw the valve complete with bracket inlet and outlet pipes 9 Transfer the bracket inlet pipe and outlet pipe to the new gas control valve 10 Fit the new gas control valve taking care not to trap wiring harness between bracket and chassis ensuring that any seals showing signs of damage or deterioration are replaced 11 Re fit spark gene...

Page 41: ...retention return and replace with new panel 7 Reassemble in reverse order 8 Check the operation of the boiler Refer to Frame 50 and 51 1 Refer to Frame 51 2 Remove the boiler front side and sealing panels Refer to frame 44 and 45 Put the control box into the servicing position Refer to Frame 46 3 Carefully remove all push on connectors and earth connections main PCB only from the printed circuit b...

Page 42: ...f the control box 5 Fit new mains switch and replace electrical connections 6 Check the operation of the boiler Refer to Frame 50 and 51 1 Refer to Frame 51 2 Remove the boiler front side and sealing panels Refer to Frame 44 and 45 Put the control box into the servicing position Refer to Frame 46 3 Pull microswitch forward to disconnect from diaphragm 4 Lift plastic retention clip and remove elect...

Page 43: ...Refer to Frame 51 2 Close all the water isolating valves CH and DHW 3 To drain the central heating circuit attach a length of hose to the drain point and open the drain valve Note Some residual water may be experienced during the replacement of components ix7442 2 3 4 As there is no direct drain for the domestic hot water circuit depending on the location of the boiler opening the lowest hot water...

Page 44: ...econnect the sensing head to the pressure relief valve 6 Re assemble in reverse order 7 Check the operation of the boiler Refer to Frame 50 and 51 68 CH AND DHW DIAPHRAGM REPLACEMENT 1 Refer to Frame 51 2 Remove the boiler front side and sealing panels Refer to Frame 44 and 45 Put the control box into the servicing position Refer to Frame 46 3 Drain the boiler water circuit Refer to Frame 67 4 Pul...

Page 45: ...f the boiler Refer to Frame 50 and 51 70 SAFETY RELIEF VALVE REPLACEMENT 1 Refer to Frame 51 2 Remove the boiler front panel Refer to Frame 44 3 Drain the boiler water circuit Refer to Frame 67 4 Put the control box into the servicing position Refer to Frame 46 5 Remove the pressure gauge sensing head from the safety relief valve 6 Undo the safety relief valve inlet and outlet union nut connection...

Page 46: ...ith U shaped clip 7 Re assemble in reverse order 8 Refill the boiler Refer to Frame 32 9 Check the operation of the boiler Refer to Frame 50 and 51 73 DIVERTER VALVE MECHANISM REPLACEMENT 1 Refer to Frame 51 2 Remove the boiler front side and sealing panels Refer to Frame 44 and 45 Put the control box into the servicing position Refer to Frame 46 3 Drain the boiler water circuits Refer to Frame 67...

Page 47: ...exchanger being careful not to damage the O rings and retain with the two allen screws 7 Refit the bypass pipe and retain with two U shaped clips 8 Re assemble in reverse order 9 Refill the boiler Refer to Frame 32 10 Check the operation of the boiler Refer to Frame 50 and 51 1 Refer to Frame 51 2 Remove the boiler front side and sealing panels Refer to Frame 44 and 45 Put the control box into the...

Page 48: ...re are two options A If it has a punctured diaphragm but is otherwise leak free then it can be left in place and a new vessel added to the return side of the CH system external to the boiler providing it is of adequate capacity and pre charge pressure B The boiler can be removed from the wall and the expansion vessel replaced 1 Refer to Frame 51 2 Drain the boiler water circuits Refer to Frame 67 ...

Page 49: ...side brass outlet connection and swivel the brass piece to clear the copper pipe 9 Remove the condensate drain point from the top of the recuperator 10 Remove the fan Refer to Frame 53 11 Remove the single fixing screw from the bottom rear of the recuperator connecting the recuperator to the back panel 12 Carefully pull the recuperator downwards to disengage the flue turret connection 13 Fit the n...

Page 50: ...nd burning On Flashing Frost demand not burning Flashing Flashing Note At all times LED 2 will be off Lockout and error conditions will be indicated by the illumination of LED 2 for a period of 10 seconds on and 2 seconds off During the 10 second on period LED 3 will flash a variable number of times 0 5 seconds on 0 5 seconds off The number of times that it flashes will define the error code as de...

Page 51: ... the NAC Replace PCB NO YES Replace NAC Replace ignition electrodes NO YES YES NO Replace NAC Can the error be reset by the reset procedure when the boiler is cold See Frame 39 NO NO YES YES NO YES Replace OH Stat Replace wiring harness Is wiring continuity OK Replace PCB YES Set CH control knob to max temperature If the OH trips again measure flow temp Over 90o C check flow thermistor Frame 72 84...

Page 52: ...switch assembly Is the pressure switch microswitch actuating pin extending a min length of 10 mm Check diaphragm Replace water set pump NO NO 82 ERROR CODE 3 WPS PPS ALARM YES YES YES NO 83 ERROR CODE 4 APS FAN ALARM Does the fault clear following the reset procedure Is there movement from the fan YES YES NO YES Run and observe operation Is there 240V AC on fan motor NO Is PCB connector fitted cor...

Page 53: ...place PCB Fit and re test Drain waterset and replace thermistor Is PCB connector fitted correctly YES Is harness continuity OK NO YES Replace PCB Replace harness 85 ERROR CODE 6 DHW THERMISTOR FAULT Unplug thermistor connector Is resistance approx 10K OHMS at 25o C Re connect and measure voltage across thermistor Is it 3 75V DC nominal YES NO NO NO YES Replace PCB Fit and re test Drain waterset an...

Page 54: ...e value of the thermistor Is it OK Inspect the heat exchanger and check for water flow Repair as necessary YES Replace thermistor Replace harness NO Fit and re test NO NO Fill and vent the system Open all isolating valves Replace thermistor NO 87 ERROR CODE 8 CONDENSATE BLOCKAGE ALARM NO Refit and re test Is there condensate in the recuperator Check this by partially unscrewing the recuperator the...

Page 55: ...908 46 Casing Bottom Panel 1 173 913 50 Gas valve gaskets 1 173 925 51 Condensate Blockage Thermistor 1 173 926 52 Overheat thermostat 1 173 927 53 Expansion vessel 1 173 928 56 Combustion Chamber Insulation Pack C24 1 173 910 C28 C32 1 173 911 57 Thermistor Waterset CH DHW 1 173 932 58 H07 781 DHW plate heat exchanger C24 1 173 544 E69 408 C28 1 170 995 H07 782 C32 1 173 545 59 Gasket Kit servici...

Page 56: ...55 SHORT LIST OF PARTS excel HE Installation and Servicing 88 SHORT LIST 19 2 5 6 1 8 41 40 50 51 52 53 58 59 60 61 57 56 20 21 9 10 17 31 30 35 26 25 33 36 27 34 29 28 43 42 45 46 44 ex7466 ...

Page 57: ...56 NOTES excel HE Installation and Servicing ...

Page 58: ...t Local Authority Building Control LABC who will arrange an inspection or contact a government approved inspector LABC will record the data and will issue a certificate of compliance If you notify via CORGI Scheme CORGI will then notify the relevant Local Authority Building Control LABC scheme on members behalf Scheme members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com withi...

Page 59: ...WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE o C HOT WATER OUTLET TEMPERATURE o C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR AL...

Page 60: ...CARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATUR...

Page 61: ...ecification without notice The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001 2000 Quality System accepted by BSI The code of practice for the installation commission...

Page 62: ...icing instructions When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers HE C24 C28 C32 ...

Page 63: ...h having a 3mm 1 8 contact separation in both poles serving only the boiler and system controls Alternatively a 3 pin UNSWITCHED socket may be used The means of isolation must be accessible to the user after installation Important Notes This appliance must not be operated without the casing correctly fitted and forming an adequate seal If the boiler is installed in a compartment then the compartme...

Page 64: ... Internal frost protection operates regardless of the position of the main switch and CH heating thermostat knob B Therefore when the boiler is not lit and used in cold weather with consequent risk of freezing the supply to the boiler should be left switched on If the system includes a frost thermostat then during cold weather the boiler should ONLY be turned OFF at the time switch if fitted The m...

Page 65: ... Faults If unable to do so or if the pressure continues to drop then contact your installer Is the fault indication light 2 alight see Reset Procedure under Faults Fan and pump run continuously but there is no attempt at ignition Check that the flue product test cap on top of the boiler is fitted correctly Operating for hot water but will not operate for central heating Check that integral program...